Footwear

ABSTRACT

A turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base ( 2 ), and a turntable ( 4 ) mounted to the base and sealed relative to the base to prevent ingress of dirt or mud into the interior of the module, the module being mountable to preformed sole structure such that the turntable is exposed through an aperture in an outer sole ( 20 ) of the structure. The use of the pre-assembled turntable module facilitates its incorporation into footwear using conventional mass production techniques for footwear.

The present invention relates to footwear and more particularly to a sole for footwear having a structure for minimising injury to the wearer as may arise from twisting or turning movements which may occur during certain sporting activities and/or for enhancing performance by assisting rotational movement of the foot to occur with body movement.

A footwear sole incorporating a turntable to minimising injuries of the type just discussed is disclosed in International patent applications PCT/AU91/00590, PCT/AU94/00002 and PCT/AU96/00634 (“the earlier applications”) of the present invention. In the earlier applications a turntable of generally circular shape is incorporated into a recess in the sole and is capable of rotation through a limited angular extent as defined by a series of inter-engaging projections and recesses between the turntable and the structure of the sole. The actual effect of the turntable in practice is to allow the sole to pivot about the turntable if the foot is turned or twisted when the turntable is in contact with the ground. The turntable is subject to a resilient bias which has the effect of returning it to its initial position relative to the sole when the sole is lifted relative to the ground.

Although the various turntable arrangements described in the earlier applications work effectively, nevertheless difficulties have arisen in adapting the turntable construction to mass production techniques conventionally used in the manufacture of footwear, particularly sporting footwear with moulded soles. To a significant extent this difficulty has inhibited the commercial application of this concept.

According to one aspect of the invention there is provided a turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base, a turntable mounted to the base for limited rotation relative to the base in each direction of rotation from a rest position, with resilient structure mounted between the turntable and base so as to cause the turntable to return to the rest position following rotation, and a sealing ring applied to the base to lie outwardly of the periphery of the turntable so that the turntable is sandwiched between the sealing ring and the base, the outer surface of the turntable being in wiping contact with the adjacent surface of the sealing ring whereby the sealing ring prevents ingress of dirt or mud into the interior of the module, the module being mountable to preformed sole structure such that the turntable is exposed through an aperture in an outer sole of the structure.

The use of a turntable module means that modules manufactured and assembled at one production facility can be supplied to a footwear manufacturer without the specialist techniques needed to produce and assemble the turntable structure. The footwear manufacturer then manufactures the outer sole in the usual way by moulding but with a recess of circular or other appropriate shape extending through the sole for receiving the turntable. The module is then applied to the sole so as to lie between the upper surface of the moulded outer sole and lower surface of the inner sole and is secured thereto.

In practice the mounting plate, turntable and sealing ring are moulded from a relatively hard material of plastic such as polyurethane (for example TPU), or nylon, or of a lightweight metal or alloy or of a combination of such materials.

Further according to the invention there is provided a turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base, and a turntable mounted to the base and sealed relative to the base to prevent ingress of dirt or mud into the interior of the module, the module being mountable to preformed sole structure such that the turntable is exposed through an aperture in an outer sole of the structure.

Still further according to the invention there is provided an article of footwear having an outer sole with a circular aperture extending therethrough, a module comprising a base, a turntable mounted to the base and sealed relative to the base to prevent ingress of dirt or mud between the turntable and the base, the module being mounted as a pre-assembled unit to structure of the sole above the outer sole such that a ground-engaging part of the turntable projects through the aperture in the outer sole.

Still further according to the invention there is provided a turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base, a turntable rotatably mounted to the base, and a sealing ring applied to the base to lie outwardly of the periphery of the turntable so that the turntable is sandwiched between the sealing ring and base with opposed surfaces of the turntable and sealing ring being in wiping contact to prevent ingress of dirt or mud into the interior of the module, the base extending outwardly beyond an outer periphery of the sealing ring to provide the base with an upper surface which can be attached to the undersurface of sole structure overlying an outer sole by adhesive connection thereto and/or by positive connection by means of fasteners extending through parts of the base externally of the sealing ring.

A preferred embodiment of the invention will now be further described by way of example only with reference to the accompanying drawings in which:

FIG. 1 is an exploded view of a turntable module in accordance with the invention;

FIG. 2 is an exploded view similar to FIG. 1 but viewed from underneath;

FIG. 3 is an underneath view of the assembled module;

FIG. 4 is a fragmentary section to an enlarged scale showing the sealing co-operation between the sealing disc and turntable;

FIG. 5 is a view similar to FIG. 4 and showing a modified sealing arrangement;

FIG. 6 is a longitudinal section through the sole part of a shoe having the turntable module of FIGS. 1 to 4 mounted therein; and

FIG. 7 is an underneath view of a turntable module in which the turntable incorporates integrally formed ground-engaging fins.

As shown in FIGS. 1 and 2 the turntable module has a base plate 2, a turntable 4, and a sealing ring 6. The co-operating surfaces of the base plate 2 and turntable 4 are formed with co-operating projections and recesses generally designated at 8, 10 respectively by which the turntable 4 is accurately located relative to the base plate 2 for rotation through limited angular extent about a central axis. A spring 12 is interposed between the base plate 2 and turntable 4 to apply a rotational bias to the turntable 4 to return it to a rest position after rotation in either direction of rotation. Although the spring 12 is shown as a coil spring, other forms of spring are also suitable. The co-operation between the projections and recesses 8, 10 is such that the turntable 4 is able to rotate through approximately 30° in each direction of rotation from the rest position.

The turntable 4 is held assembled to the base plate 2 by a rivet 14 located on the axis of rotation. After assembly of the turntable 4 to the base plate 2, the sealing ring 6 is applied to the base plate 2 around the periphery of the turntable 4 and is secured to the base plate 2 by adhesive, by ultrasonic welding, or by a snap fastening. The sealing ring 6 is of a stepped cross-section (see FIG. 4) and overlies the outer periphery of the turntable 4 to form therewith a wiping seal to prevent ingress of dirt and mud between the turntable 4 and base plate 2 and which might otherwise impede proper action of the turntable. To further improve the sealing action, in the modification shown in FIG. 5 the periphery of the turntable 4 is provided with one or more V-shaped ribs 15 which engage in grooves of corresponding cross-section in the adjacent face of the sealing ring 6 (or alternatively the ribs could be formed on the sealing ring and the grooves in the turntable). This improved sealing action is particularly beneficial for shoes which may also be worn on the beach or for shoes such as soccer shoes which are specifically intended for use in muddy situations. Although the use of the sealing ring (either with or without the ribs/grooves) is preferred sealing could, however, be achieved in an alternative manner.

A moulded tread disc 16 is applied to the outer surface of the turntable 4, for example by adhesive, and encloses the head of the rivet 14.

The base plate 2 of the module includes radially projecting lugs 2 a which assist in the installation of the module to the sole of the shoe to provide an anchorage between the base plate and sole which will withstand the torsional forces applied to the base plate. The module is mounted to sole structure internally of the outer sole and the tread disc 16 of the turntable projects through a circular recess in the outer sole to extend slightly proud of the undersurface of the outer sole. The module can be adhesively attached to the internal sole structure with the adhesive being between the upper face of the base plate and the adjacent face of the sole structure and/or by riveting or screwing through the lugs 2 a. The method of attachment will depend on the specific construction used for the internal sole structure. A simple and inexpensive form of internal sole structure may consist simply of an inner sole of cardboard or similar material. In that case the module may be applied directly against the underside of the inner sole to be anchored in position by adhesive and also by screws extending through the inner sole and into the lugs 2 a. In an internal sole structure having a relatively thick moulded mid sole or moulded inner sole, the moulding is formed with a recess in its underside corresponding to the outer periphery of the base plate and into which the module fits and is locked against rotation as a result of the inter-fit between the two components; in that case adhesive between the base plate and the base of the recess may be sufficient to hold the module in the recess without the need for fasteners extending into the lugs 2 a. FIG. 6 shows by way of example the module fitted into a recess of corresponding shape formed in the underside of a mid sole 18 moulded in a suitable material such as EVA.

When the module has been applied to the internal sole structure (specifically to the inner sole or mid sole depending on the actual construction), a preformed outer sole 20 with an aperture to receive the tread disc is applied over the internal sole structure and is secured thereto in conventional fashion. If the lugs 2 a lie directly against the upper surface of the outer sole as may arise in a construction in which the module is mounted directly to the underside of a relatively thin insole, the under surface of the lugs may also be adhered to the upper surface of the outer sole to further improve the anchorage against torsional forces.

Although as shown, the base plate 2 is of circular shape extended by the radial lugs 2 a, the base plate can be shaped externally of the sealing ring 6 into any suitable shape not only to facilitate anchorage to the internal sole structure in the same way as does the lugs 2 a but also to provide reinforcement for adjacent parts of the sole structure and this may be of particular benefit when the module is applied directly against a relatively thin inner sole.

The base plate, turntable and sealing ring are moulded or otherwise formed from a relatively hard material (or combination of materials) such as those previously specified.

The tread disc will be moulded out of material equivalent to that of the outer sole which in the case of shoes designed for sports such as basketball or netball will be of a comparatively resilient material. It is however to be understood that the turntable could be integrally formed with a suitable tread disc or other ground-engaging formation such as fins, studs or spikes. FIG. 7 shows a module with a turntable 4 having integral fins 22.

As shown in FIG. 6, the turntable module is mounted within the sole so that the turntable 4 with tread disc 16 lies predominantly beneath the ball of the foot. It is however to be understood that the module could be mounted in other parts of the sole, for example the heel part. It is possible for separate modules to be mounted in the ball part and heel part of the same shoe.

The turntable module described herein can be manufactured and assembled at a single source and then supplied to a range of footwear manufacturers for incorporation into their footwear. Although the tread disc 16 when applied to the turntable 4 can be considered to form an integral part of the turntable, the module may be supplied to the manufacturer absent the tread disc as, in practice, the tread pattern on the disc will be complimentary to that of the outer sole and the disc itself will be moulded in the same material. In that case the tread disc may conveniently be provided by the shoe manufacture as a simple moulding which is applied to the turntable prior to incorporation of the module into the sole structure.

Although the turntable module described herein represents the preferred form of the invention, nevertheless some of the features of the module do have broader applicability. For example, in a modified arrangement the turntable may be mounted for free rotation on the base plate without any restriction as to the angular extent of the rotation and without a spring bias acting to return the turntable to a rest position. This arrangement may be suitable for a limited range of applications although it is to be understood that the described arrangement in which the turntable is rotatable through a restricted angle in either direction from a rest position and is returned to that rest position by a spring bias is preferred.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

The embodiments have been described by way of example only and modifications are possible within the scope of the invention. 

1. A turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base, a turntable mounted to the base for limited rotation relative to the base in each direction of rotation from a rest position, with resilient structure mounted between the turntable and base so as to cause the turntable to return to the rest position following rotation, and a sealing ring applied to the base to lie outwardly of the periphery of the turntable so that the turntable is sandwiched between the sealing ring and the base, the outer surface of the turntable being in wiping contact with the adjacent surface of the sealing ring whereby the sealing ring prevents ingress of dirt or mud into the interior of the module, the module being mountable to preformed sole structure such that the turntable is exposed through an aperture in an outer sole of the structure.
 2. A module according to claim 1, wherein the turntable of the pre-assembled unit includes a tread disc to project through the aperture in the outer sole for contact with the ground.
 3. A module according to claim 1, wherein the adjacent surfaces of the turntable and sealing ring in wiping the contact include at least one annular rib extending from one of the surfaces into an annular groove of corresponding section in the other of said surfaces.
 4. A module according to claim 1, wherein the base is of generally circular shape and includes lugs projecting radially outwardly to assist in the attachment of the module to the sole structure.
 5. A module according to claim 1, wherein the base extends outwardly relative to the sealing ring to assist in the attachment of the module to the sole structure and/or to provide reinforcement for the sole structure.
 6. A method of manufacturing an article of footwear, comprising providing an internal sole component, mounting a module according to any one of the preceding claims to a lower facing surface of the internal sole component, providing an outer sole component having an aperture sized and positioned so as to align with the turntable of the module, and applying the outer sole component to the underside of the internal sole component such that a ground-engaging part of the turntable projects through the aperture.
 7. A method according to claim 6, wherein the internal sole component to which the module is attached is an inner sole.
 8. A method according to claim 6, wherein the internal sole component to which the module is attached is a mid sole.
 9. A method according to claim 6, wherein the internal sole component to which the module is attached is of moulded construction and includes in its undersurface a recess of complimentary shape to that of the base such that the base sits within the recess.
 10. A method according to claim 6, wherein the module is attached to the internal sole component by adhering the base to the internal sole component and/or by positively fastening the base to the internal sole component by fasteners extending through parts of the base externally of the sealing ring.
 11. (canceled)
 12. An article of footwear having an outer sole with a circular aperture extending therethrough, a module comprising a base, a turntable mounted to the base and sealed relative to the base to prevent ingress of dirt or mud between the turntable and the base, the module being mounted as a pre-assembled unit to structure of the sole above the outer sole such that a ground-engaging part of the turntable projects through the aperture in the outer sole.
 13. A turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base, a turntable rotatably mounted to the base, and a sealing ring applied to the base to lie outwardly of the periphery of the turntable so that the turntable is sandwiched between the sealing ring and base with opposed surfaces of the turntable and sealing ring being in wiping contact to prevent ingress of dirt or mud into the interior of the module, the base extending outwardly beyond an outer periphery of the sealing ring to provide the base with an upper surface which can be attached to the undersurface of sole structure overlying an outer sole by adhesive connection thereto and/or by positive connection by means of fasteners extending through parts of the base externally of the sealing ring.
 14. A module according to claim 13, wherein the base is extended outwardly of the sealing ring by a plurality of radially extending lugs.
 15. A module according to claim 13, wherein the turntable includes a ground-engaging tread disc.
 16. A module according to claim 15, wherein the turntable comprises a turntable disc rotatably mounted to the base by a rivet extending through the turntable and base, and the tread disc is applied to the turntable disc to project therefrom and to enclose the rivet.
 17. A module according to claim 13, wherein the turntable is in the form of a disc including integrally formed ground-engaging structure extending axially downwardly from the disc, and the turntable disc is rotatably mounted to the base by a rivet extending through the turntable disc and the base.
 18. A turntable module for incorporation into a footwear sole as a pre-assembled unit, the module comprising a base, and a turntable mounted to the base and sealed relative to the base to prevent ingress of dirt or mud into the interior of the module, the module being mountable to preformed sole structure such that the turntable is exposed through an aperture in an outer sole of the structure.
 19. An article of footwear having an outer sole component, a turntable module according to claim 1, wherein the turntable module is mounted as a pre-assembled unit to the underside of an internal sole component above the outer sole, with a ground-engaging part of the turntable projecting through an aperture formed in the outer sole.
 20. An article of footwear according to claim 19, wherein the internal sole component to which the module is attached is an inner sole.
 21. An article of footwear according to claim 19, wherein the internal sole component to which the module is attached is a mid sole.
 22. An article of footwear according to claim 19, wherein the internal sole component to which the module is attached is of moulded construction and includes in its underside a recess of complimentary shape to that of the base such that the base sits within the recess.
 23. An article of footwear according to claim 22, wherein the complementary shaping of the recess and base is such as to positively lock the base in the recess against rotation.
 24. An article of footwear according to claim 19, wherein the module is attached to the internal sole component by adhering the base to the internal sole component and/or by positively fastening the base to the internal sole component by fasteners extending through parts of the base externally of the sealing ring.
 25. An article of footwear according to claim 19, wherein the base extends externally of the sealing ring to provide reinforcement for an adjacent part of the sole structure.
 26. An article of footwear having an outer sole component, a turntable module according to claim 13, wherein the turntable module is mounted as a pre-assembled unit to the underside of an internal sole component above the outer sole, with a ground-engaging part of the turntable projecting through an aperture formed in the outer sole. 